Title of Invention

METHOD FOR INCREASING THE CAPACITY OF AN INSTALLATION USED TO CARRY OUT AN INDUSTRIAL PROCESS

Abstract The invention relates to a method for increasing the capacity of an installation (1) used to carry out an industrial process in an economical and sustainable manner. Said method consists of the following steps; process variables (P1 ... P10) relevant to the capacity of the installation (1) are determined; said process variables (P1 ... P10) are monitored during variable operating conditions of the installation; and a very small control reserve of the control loops of the installation is established on the basis of the monitored process variables (P1 ... P10).
Full Text Description
Method for increasing the capacity of an installation used
to carry out an industrial process
The invention relates to a method for increasing the
capacity of an installation used to carry out an industrial
process.
An increase of a few percentage points in the capacity of an
installation for carrying out an industrial process results
as a rule in a disproportionately high improvement in
profits for the operator of the installation. This type of
industrial process can typically be a process with
production lines which run through the installation, such as
lines for the manufacture of paper, textiles, plastics or
metal foils. With such processes the capacity of the process
is determined by the speed of the track, e.g. measured in
meters per second.
When a machine part for a machine contained in the
installation pr a complete part of the installation is
designed for such an installation, this is mostly done on
the basis of similar machines or parts of the installation,
taking into account a certain amount of capacity reserve.
However, under the operating conditions which actually occur
in the installation, the loads imposed on the machine or the
parts of the installation are mostly different to those in
previously known installations. It is thus not possible to
say with any certainty in what way it is possible to
increase the capacity of an installation without overloading
one or more parts of the installation.
Previous measures for increasing the capacity in such
installations, especially in complex installations such as

installations for carrying out continuous processes for
manufacturing of goods on a production line have also
generally lacked long-term sustainability.
The object of the present invention is therefore to specify
a method which allows the capacity of an installation to be
increased in a sustained and economical manner.
This object is achieved in accordance with the invention by
a method in accordance with claim 1. Advantageous
embodiments of the method are the object of subclaims 2 to 9
in each case.
The invention in this case is based on the knowledge that
previous measures for increasing the capacity in
installations has always only been based on considering
particular points in the installation and has therefore as a
rule ignored long-term sustainability. The determination of
the process variables relevant to the capacity of the
installation envisaged by the invention and the recording of
these variables under changing operating conditions
guarantees that all aspects of the influencing factors
restricting the capacity of the installation will be taken
into consideration. Changing operating conditions here are
taken to mean the operating conditions occurring during
regular operation of the installation, i.e. in the case of a
paper machine the operation of the machine with paper of
different qualities and types for example. This avoids
looking at only a few specific individual aspects of the
installation such as the drive system, under a number of
specific operating conditions, but not taking into account
other factors and operating conditions which dictate the
capacity. As a result this makes not just a short-term
increase, but a sustained increase in capacity possible.

The smallest control reserve of the control loops determines
the increase in capacity which can be obtained without any
further measures. This guarantees that first of all the
existing capacity reserves that can be secured are checked
and these reserves are secured if necessary. This represents
the increase in capacity that can be most easily achieved
from the economic standpoint.
If the aim is to use additional measures to obtain an
increase in capacity which goes beyond the existing capacity
reserve, this can be done by defining a capacity increase
target for the installation, determining the necessary
control reserves in the control loops for the desired
increase in capacity and determining the control loops with
a control reserve which is too low for the desired capacity
increase.
From the number of control loops with control reserves which
are too low it is already evident v/hat effort will be needed
for further investigations and possibly also for the
implementation of measures for increasing capacity. With a
large number of control loops a decision can be taken under
some circumstances to define a smaller increase in capacity,
so that further investigations are only required for the
correspondingly smaller number of control loops.
According to an advantageous embodiment of the invention
further steps include a technical and/or technological
investigation of the control loops with a control reserve
which is too small and formulation of measures for producing
the control reserves needed in each case by relieving the
load on the relevant control loops and/or by replacing
components in the relevant control loops by higher-
performance components

These measures can finally be evaluated from a technical and
or commercial standpoint. On the basis of this evaluation
the decision process for the implementation of the
improvement measures can be simplified and a solution found
which is the optimum solution for the operator of the
installation from the cost/benefits standpoint.
Overall the sequence of the above steps ensures that
priority is given to dealing with the points for which there
is the greatest potential for improvement or for which the
cost effectiveness of a conversion is the greatest. At the
same time this process allows available capacity reserves to
be secured in the most economical way even in a highly-
complex installation.
The method in accordance with the invention is especially
suitable for increasing the capacity in an installation for
executing a continuous process, especially a process for
manufacturing,goods on production lines, e.g. paper,
textiles, plastic or metal foils, for which the capacity is
determined by the speed of the production line.
The invention as well as a further advantageous embodiments
of the invention in accordance with the features of the
subclaims are explained in more detail below with reference
to exemplary embodiments in the figures. The accompanying Figures show:
FIG 1 a recording of process variables in an installation
for manufacturing paper,
FIG 2 a representation of an inventive process sequence
depicted as a flowchart,
FIG 3 a basic diagram for determining the process
variables relevant for the capacity of an

installation,
FIG 4 a diagram of the process variables relevant for a
paper machine,
FIG 5 a machine velocity/moment diagram for determining
the control reserve for a drive motor and
FIG 6 a determination of the control reserve for the drive
motor of FIG 5.
FIG 1 shows an installation 1 for manufacturing paper. The
installation 1 comprises a wide diversity of installation
parts which are needed for the different steps in the
production process for paper, for example a material
preparation system la, a paper machine'1b, a roller/calendar
1c, roll cutter 1d and cross cutter 1e. The paper runs as a
production line 8 through major parts of the installation 1.
The installation 1 features a plurality of drive components
11, automation components 12 and energy supply components 13
for driving, supplying power to and controlling the
different components in the production process.
A device 2 is used to determine the control reserves in the
installation 1. The device 2 features a recording unit 3, an
evaluation unit 4, an input unit 7 and an output unit 5.
The recording unit 3 is used for recording process variables
P1 ...P10 of the paper production process on the
installation 1. This can for example involve measurement
signals which are recorded using signal generators already
present and/or to be provided in the installation 1.
The process variables can originate from a wide diversity of
sources of the processor and be present in any form,

including different forms, e.g. analog, binary, numeric
and/or as a changeable physical variable. The evaluation
unit 4 is used for determining the control reserves in the
control loops of the installation 1. To this end a large
number of characteristic capacity curves for a plurality of
components, especially standard components occurring in the
installation are stored in a memory of the evaluation unit
4. The output unit 5 can be used to present the control
reserves for display. Furthermore the device 2 features an
input unit 7 for entering a desired capacity increase into
the installation 1.
In FIG 2 the method in accordance with the invention is
explained on the basis of a flowchart. The procedure is
advantageously carried out by a service provider who has the
appropriate know-how and technical facilities to do so.
In a first step 31 - as explained in detail in FIG 3 and 4 -
the process variables relevant for a capacity of the
installation are determined. In a second step 32 these
process variables are recorded under changing operating
conditions of the installation, and in a third step 33 - as
illustrated by the examples in FIG 5 and 6 - a smallest
control reserve of the control loops of the installation is
determined on the basis of the recorded process variables.
This control reserve can be used to increase the capacity of
the installation without any appreciable investment outlay.
In a step 33a a check is therefore made as to whether an
increase in capacity beyond this smallest control reserve is
desired. If this is not required, the procedure can be ended
in step 39b, by securing the available capacity reserve.
If an increase in the capacity of the installation which
exceeds the reserve is required, in a further procedural

step 34 such a desired capacity increase of the installation
can be defined. In a further step 35 the control reserves
necessary for the desired increase in capacity are
determined in the control loops of the installation and in a
further step 36 the control loops with a control reserve
which is too small for the desired capacity increase are
determined.
For the control loops with a control reserve which is too
small, technical and/or technological investigations of the
control loops can be performed in a further step 37 to
establish the control reserves needed in each case by
relieving the load on the relevant control loops and/or
through replacing components in the relevant control loops
by more powerful components. In a further step 38 a
technical and/or commercial evaluation of these measures can
be undertaken, on the basis of which a final implementation
of the measures is undertaken in step 39a.
The process variables relevant for the capacity of an
installation can be easily established in this way by
applying in the more general sense the method of "cutting
free" known per se from technical mechanics.
This is done in a first step by determining a process
variable representing the capacity of the installation. in
the case of an installation for paper production this might
typically be the speed of the paper in the installation
In a next step, as basically shown in FIG 3, a core process
6 of the installation is defined and all interfaces 21 - 25
of the core process 6 to the ancillary processes 41 - 45
surrounding it (e.g. ancillary processes for energy, water
and compressed air supply) are determined and investigated
for their effect in relation to this representational

process variable. This can be done by measuring the physical
effects (e.g. forces, currents, fields, throughflows,
pressures) at these interfaces. These physical effects of
process variables can be measured by signal generators
already present and/or to be provided, which if necessary
must be accommodated at the interfaces.
If there is a effect relationship with the representational
process variable at an interface, a process variable which
is relevant to the capacity of the installation is present
at this interface and a more precise technical investigation
is undertaken for the components of the ancillary process to
determine the control reserve. The interfaces which do not
have an effect relationship are not considered any further
and instead the interfaces the interfaces are drawn closer
to the core process or moved to within the core process and
an investigation is conducted at these new interfaces for an
effect relationship with the representational process
variable. In this case too interfaces with an effect
relationship to the representational process variable are
identified as relevant process variables for which in
further steps more precise technical investigations for
determining the control reserves are to be performed.
Such a systematic, step-by-step "drawing closer" of the
interfaces of the ancillary process into the core process
ensures that all of the process variables relevant for
determining the capacity of the installation are determined
not only in the area of the core process but also in the
area of the ancillary processes.
In the case of an installation for paper production the
subprocess running on the paper machine can be defined as
the core process for example. Interfaces to ancillary

processes with effect relationships to the speed of the
paper passing through the installation are then to be found
in the area of material and energy flows, for example for
feeding energy, steam, water, fibers, chemicals and
additives as well as for removal of water, condensate and
waste heat. The relevant process variables in the area of
the ancillary processes are thus in this case - as shown in
FIG 4 - the supply of energy 51 (e.g. measured as power P),
the supply of steam 52 (measured as volume per unit of
time), the supply of water 53 (measured as volume per unit
of time) the supply of fibers 54 (measured as mass per unit
of time), the supply of chemicals 55 (measured as mass per
unit of time) the removal of water 56 (measured as volume
per unit of time), the removal of condensate 57 (measured as
volume per unit of time) and the removal of waste heat 58
(measured as power P). These relevant process variables can
only be recorded under changing operating conditions of the
installation, e.g. for different qualities and types of
paper, and - as explained below - the control reserves in
the control loops of the installation for paper production
determined.
An advantageous procedure for determining the control
reserve for an electric motor for driving a paper machine of
installation 1 in accordance with FIG. 1 will be explained
with the aid of FIG 5 and FIG. 6. The procedure is basically
also applicable to other control loops of the installation
(e.g. steam, vacuum, coating).
At a defined velocity v of the paper in the paper machine a
defined load (moment) M is present at the electric motor.
This operating point defines a specific class K in the
speed/load plane v/M shown in FIG 4. For each class K the
time (duration) T is counted in which the motor is operated

in this class and shown in a plane perpendicular to the v/M
plane. The classes K with the longest times can thus be
determined. These can subsequently be approximately
described by a linear relationship between moment M and
machine velocity v described and represented by a straight
line gradient G. Basically the relationship between moment M
and machine velocity v can naturally also be described
through complex functions.
The diagram in FIG 6 shows the moment M of the motor over
the velocity v of the machine, with these two parameters
being approximated by a linear relationship in accordance
with FIG. 4 represented by the straight line gradient G.
With a speed-regulated drive the maximum power of a motor or
a converter (depending on which is the smaller) is a
hyperbolic curve HK in the velocity/moment plane v/M. The
distance RV of this hyperbolic curve HK to the straight line
gradient G is a measure for the control reserve and thereby
for the maximum possible increase in speed.
In the case of determination of the control reserve for
example with regard to the positioning of a vacuum or steam
control valve, velocity and load of an ancillary drive, of
fluid streams etc. the machine velocity can also be plotted
by the position of the valve, the speed of the ancillary
drive or the fluid stream instead of via the load, the
duration determined and the approximately linear or complex
relationship with the velocity v determined.
The processes to be considered in the case of an
installation with a continuous production process, e.g. an
installation for paper production, are as a rule not very
dynamic. The dynamic components in the process variables are
not even of primary interest for the determination of the

control reserves. Of greater interest instead is the average
long-term behavior of the process variables. The process
variables are therefore preferably filtered (appr. 2 s) and
only sampled appr. every 5s.
Preferably an online evaluation of the recorded data with
subsequent data compression is undertaken for a subsequent
offline evaluation of the recorded data.

WE CLAIM:
1. A method for increasing the capacity of an installation (1) for carrying
out a continuous production process, comprising the steps of:
- determining the process variables (P1... P10) relevant for the
capacity of the installation (1),
- recording the process variables (P1 ... P10) under changing
operating conditions of the installation,
- determining a smallest control reserve of the control loops of
the installation on the basis of the recorded process variables
(P1 ... P10), wherein the operating points of the process
variables with the longest duration times are determined for
determining the smallest control reserve.
2. Method as claimed in claim 1, with the steps :
- defining a desired increase in the capacity of the installation,
- determining the control reserves in the control loops of the
installation necessary for the desired capacity increase,
- determining the control loops with a control reserve which is
too small for the desired capacity increase.

3. Method as claimed in claim 2 with the steps of:
- technical system and/or technological investigation of the
control loops with a control reserve which is too small and
- formulation of measures for producing the control reserves
required in each case by relieving the load on the relevant
control loops and/or by replacing components in the relevant
control loops by higher-capacity components.
4. Method as claimed in clam 3 with the step :
- performing a technical and/or commercial evaluation of the
measures.
5. Method as claimed in claim 1, with a core process being defined for
determining the relevant process variables and interfaces of the core
process with ancillary processes surrounding them being investigated
for an effect relationship with a process variable representing the
capacity of the installation.

6. Method as claimed in one of the previous claims, wherein the
installation (1) concerned is an installation for execution of a
continuous process, especially a process for manufacturing of
production line goods (8) e.g. paper, textiles, plastic or metal foils.
7. Method as claimed in claim 6, with the capacity of the installation
being determined by the speed of the production line (8).
8. Method as claimed in any one of the previous claims, with the method
being executed by a service provider company.
9. Method as claimed in one of the previous claims, with the process
variables being filtered approximately every 2 seconds and sampled
approximately every 5 seconds when they are recorded.

The invention relates to a method for increasing the capacity of an
installation (1) used to carry out an industrial process in an economical and
sustainable manner. Said method consists of the following steps; process
variables (P1 ... P10) relevant to the capacity of the installation (1) are
determined; said process variables (P1 ... P10) are monitored during
variable operating conditions of the installation; and a very small control
reserve of the control loops of the installation is established on the basis of
the monitored process variables (P1 ... P10).

Documents:

2523-KOLNP-2005-CORRESPONDENCE.pdf

2523-KOLNP-2005-FORM-27.pdf

2523-kolnp-2005-granted-abstract.pdf

2523-kolnp-2005-granted-claims.pdf

2523-kolnp-2005-granted-correspondence.pdf

2523-kolnp-2005-granted-description (complete).pdf

2523-kolnp-2005-granted-drawings.pdf

2523-kolnp-2005-granted-examination report.pdf

2523-kolnp-2005-granted-form 1.pdf

2523-kolnp-2005-granted-form 18.pdf

2523-kolnp-2005-granted-form 2.pdf

2523-kolnp-2005-granted-form 3.pdf

2523-kolnp-2005-granted-form 5.pdf

2523-kolnp-2005-granted-gpa.pdf

2523-kolnp-2005-granted-priority document.pdf

2523-kolnp-2005-granted-reply to examination report.pdf

2523-kolnp-2005-granted-specification.pdf

2523-kolnp-2005-granted-translated copy of priority document.pdf

2523-KOLNP-2005-PA.pdf


Patent Number 228786
Indian Patent Application Number 2523/KOLNP/2005
PG Journal Number 07/2009
Publication Date 13-Feb-2009
Grant Date 11-Feb-2009
Date of Filing 07-Dec-2005
Name of Patentee SIEMENS AKTIENGESELLSCHAFT
Applicant Address WITTELSBACHERPLATZ 2, 80333 MUNCHEN
Inventors:
# Inventor's Name Inventor's Address
1 CHRISTIAN-MARIUS WEGNER ORTERWEG 3 91522 ANSBACH
2 STEFAN HAAKS BRAHMSSTR. 5 91052 ERLANGEN
3 GERD MICHAELIS AUF DER HOH 4 91096 MOHRENDORF
PCT International Classification Number G06F 17/60
PCT International Application Number PCT/EP2004/006258
PCT International Filing date 2004-06-09
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 103 26 428.0 2003-06-10 Germany